JP5881423B2 - Mats and equipment with mats - Google Patents

Description

  Anti-contamination devices such as catalytic converters for gasoline engines have been known for over 30 years. The use of other pollution control devices, including diesel oxidation catalysts (DOC's), diesel particulate filters (DPF's), and selective catalyst reduction devices (SCR's) due to stricter regulations on diesel vehicles in recent years Increased rapidly. The pollution control device generally includes a metal housing or casing, in which the pollution control element is firmly mounted by a resilient and flexible mounting mat. Catalytic converters, including diesel oxidation converters, contain a catalyst that is normally coated onto a monolithic structure. Metal monoliths are also known, but monolithic structures are typically ceramic. Catalysts in gasoline engines oxidize carbon monoxide and hydrocarbons, reduce nitrogen oxides, and suppress air pollution. The diesel oxidation catalyst oxidizes the soluble organic components of soot particles and any carbon monoxide present.

  Diesel particulate filters or traps are typically wall flow filters, and typically have a honeycomb monolithic structure made from a porous crystalline ceramic material. Alternating cells of a honeycomb-like structure are typically embedded so that exhaust gas enters one cell and is forced through the porous walls of one cell and exits the structure through adjacent cells. . In this way, small soot particles present in the diesel exhaust are recovered. Sometimes the temperature of the exhaust gas rises above the incineration temperature of the soot particles so that the soot particles are burned. This process is called “regeneration”.

  A selective catalytic reduction device is similar in structure and function to a catalytic converter (ie, reduces NOx). Before the gas or liquid reducing agent (typically ammonia or urea) reaches the selective catalytic reduction device monolith, the gas or liquid reducing agent (typically ammonia or urea) is added to the exhaust gas. The mixed gas causes a reaction between the NOx emissions and ammonia or urea. This reaction converts NOx emissions to pure nitrogen and oxygen.

  Monoliths used in pollution control devices, especially ceramic pollution control monoliths, are brittle and are susceptible to damage and breakage due to vibration or impact. Ceramic antifouling monoliths generally have a coefficient of thermal expansion that is an order of magnitude lower than the metal housing that contains them. This means that as the pollution control device is heated, the gap between the inner peripheral wall of the housing and the outer wall of the monolith increases. Despite the metal housing undergoing smaller temperature changes due to the thermal insulation effect of the mat, the higher the coefficient of thermal expansion of the metal housing, the housing expands faster than the ceramic monolith and expands to a larger peripheral size To do. Such thermal cycling occurs hundreds of times during the lifetime and use of the pollution control device.

  To avoid damage to the ceramic monolith due to road impact and vibration, compensate for the difference in thermal expansion, and prevent exhaust gases from passing between the monolith and the metal housing (thus bypassing the catalyst) A mounting mat is disposed between the monolith and the metal housing. These mats provide sufficient pressure to hold the monolith in place over the desired temperature range, but not enough pressure to damage the ceramic monolith. Known antifouling mounting mats include intumescent and non-intumescent sheet materials composed of inorganic (eg, ceramic) fibers and organic and / or inorganic binders.

  Some of the components of the exhaust system used in the exhaust system of an automobile (for example, an automobile having an internal combustion engine) use a heat insulating material in the gap between the double walls that are parts of the exhaust system.

  The pollution control device typically must reach a certain temperature (eg, 250 ° C. or higher) before it begins “ignition” or oxidation of carbon monoxide and hydrocarbons. They are therefore preferably located close to the engine. In addition, insulation is typically provided between the pollution control device and the converter housing, generally to minimize engine heat loss and thereby reduce the time that "ignition" occurs. It is also preferred to insulate the parts of the exhaust system between the air and the pollution control device. This is particularly important to meet increasingly stringent atmospheric environmental standards when first starting a car engine, especially in cold weather.

  Thus, the insulation is typically placed in the terminal cone region of the catalytic converter. The terminal cone region typically has a double wall structure with an outer metal cone and an inner metal cone with a gap defined between the two cones. Insulation can be placed in the gap between the inner and outer metal housings. The heat insulating material may have a mat shape or a three-dimensional shape. Various insulation materials have been disclosed for use in exhaust system components.

  Additional mounting mats and insulations are desired, including those with improved flexibility, reduced fiber shedding, and / or relatively low organic content.

  In one aspect of the present invention, a mat is provided that includes a nonwoven layer having first and second major surfaces that normally face each other and a first polymer layer. The nonwoven fabric layer contains inorganic fibers. The first polymer layer is attached so as to be in contact with at least a part of the inorganic fibers forming the first main surface. The first polymer layer includes at least one vacuum formed suction hole and preferably a plurality of vacuum formed suction holes formed through the polymer layer. The “suction hole” refers to a hole formed through the polymer layer. When the polymer layer is heated to the softening point and / or the melting point, a suction hole penetrating the polymer film is formed by vacuum.

In a first exemplary embodiment, the present disclosure
A non-woven fabric layer having first and second main surfaces facing each other, wherein the non-woven fabric layer contains inorganic fibers;
A mat comprising: a first three-dimensional polymer layer attached to the first main surface;
An article including a fireproof cloth surrounding such a mat will be described.

In some embodiments, the inorganic fiber layer ^has a basis weight in the range of ^{800g / m 2 ~8500g / m 2} . Typically, the mat has an organic content of no more than 7 (6, 5, 4, 3, 2, 1, or even zero) weight percent, based on the total weight of the nonwoven layer. Typically, the average thickness of the first polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it ranges from 10 micrometers to 25 micrometers).

In a second exemplary embodiment, the present disclosure
A non-woven fabric layer having first and second main surfaces facing each other, wherein the non-woven fabric layer contains inorganic fibers;
A first three-dimensional polymer layer adhering to the first main surface;
A mat that includes an expandable layer having first and second main surfaces that normally face each other, wherein the first main surface of the expandable layer adheres to the first main surface of the nonwoven fabric layer. To do. Typically, the nonwoven layer has an organic content of 7 (6, 5, 4, 3, 2, 1, or even zero) weight percent or less, based on the total weight of the mat. In some embodiments, the inorganic fiber layer ^has a basis weight in the range of ^{800g / m 2 ~8500g / m 2} . Typically, the average thickness of the first polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it ranges from 10 micrometers to 25 micrometers).

In a third exemplary embodiment, the present disclosure
Inorganic fibers,
A non-woven expandable layer having first and second major surfaces that normally face each other, comprising an expandable material;
A mat including the first three-dimensional polymer layer attached to the first main surface will be described. In some embodiments, the inorganic fiber layer ^has a basis weight in the range of ^{800g / m 2 ~8500g / m 2} . Typically, the nonwoven layer has an organic content of no more than 7 (6, 5, 4, 3, 2, 1, or even zero) weight percent, based on the total weight of the nonwoven layer. Typically, the average thickness of the first polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it ranges from 10 micrometers to 25 micrometers).

In a fourth exemplary embodiment, the present disclosure
A non-woven fabric layer having first and second main surfaces facing each other, wherein the non-woven fabric layer contains inorganic fibers;
A mat including a first three-dimensional polymer layer attached to the first main surface,
A mat having at least one laser cut edge is described. Typically, the mat has an organic content of no more than 7 (6, 5, 4, 3, 2, 1, or even zero) weight percent, based on the total weight of the nonwoven layer. Typically, the average thickness of the first polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it ranges from 10 micrometers to 25 micrometers). In some embodiments, the inorganic fiber layer ^has a basis weight in the range of ^{800g / m 2 ~8500g / m 2} .

  Mats and articles comprising the mats described herein can be used, for example, in pollution control and thermal insulation applications (eg, exhaust systems (eg, exhaust pipes, pollution control device inlet or outlet cones, or internal combustion engine engines). Useful in insulating various parts of the exhaust manifold). Exemplary pollution control devices include a pollution control element (eg, catalytic converter, diesel particulate filter or selective catalyst reduction element) that is mounted in a casing with the nonwoven mat described herein. Exemplary exhaust systems include a double wall exhaust component and a mat or an article comprising a mat as described herein, wherein the article or mat is disposed in a gap between the walls of the double wall exhaust component. Has been.

In another embodiment, the present disclosure describes an exhaust system that includes a double wall exhaust component and a mat disposed in a gap between the walls of the double wall exhaust component, the mat comprising:
A non-woven fabric layer having first and second main surfaces facing each other, wherein the non-woven fabric layer contains inorganic fibers;
And a first three-dimensional polymer layer attached to the first main surface. Typically, the nonwoven layer has an organic content of no more than 7 (6, 5, 4, 3, 2, 1, or even zero) weight percent, based on the total weight of the nonwoven layer. Typically, the average thickness of the first polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it ranges from 10 micrometers to 25 micrometers). In some embodiments, the inorganic fiber layer ^has a basis weight in the range of ^{800g / m 2 ~8500g / m 2} .

In another embodiment, the present disclosure provides:
A non-woven fabric layer having first and second main surfaces normally facing each other, the non-woven fabric layer comprising inorganic fibers having first and second main surfaces facing normally;
A pollution control device is described that includes a pollution control element mounted in a casing with a mat that includes a first three-dimensional polymer layer that adheres to such a first major surface. Typically, the nonwoven layer has an organic content of no more than 7 (6, 5, 4, 3, 2, 1, or even zero) weight percent, based on the total weight of the nonwoven layer. Typically, the average thickness of the first polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it ranges from 10 micrometers to 25 micrometers). In some embodiments, the inorganic fiber layer ^has a basis weight in the range of ^{800g / m 2 ~8500g / m 2} .

In another embodiment, the present disclosure provides:
An object having a radius r (eg, a pollution control element);
Without physical overlap (typically within 95 percent of 2πr, and in some embodiments within 96, 97, 98, or even 99 percent of 2πr) A mat that is wound around (eg, a mat described herein);
A non-woven fabric layer having first and second main surfaces facing each other, wherein the non-woven fabric layer contains inorganic fibers;
An article including the first three-dimensional polymer layer adhering to the first main surface is described.

  Advantages of exemplary embodiments of the nonwoven mats and articles described herein include reduced fiber shedding due to the presence of the polymer layer. The polymeric layers associated with the nonwoven mats and articles described herein can optionally provide a better adhesion surface to the surfaces of the nonwoven mats and articles as compared to the fiber layers therein, and further, for example, a diameter of 7 When wound around a 5 cm rod, the nonwoven fabric layer may be prevented from cracking or breaking.

1 is a cross-sectional view of an exemplary mat described herein. FIG. 1 is a cross-sectional view of an exemplary mat described herein. FIG. 1 is a cross-sectional view of an exemplary mat described herein. FIG. 1 is a perspective view of an exemplary pollution control device described herein. FIG. 1 is a perspective view of an exemplary pollution control device described herein. FIG. 1 is a longitudinal cross-sectional view of an exemplary exhaust pipe described herein. FIG. The digital image of the polymer layer of the mat | matte of Example 1 with the magnifications of 50 times and 200 times with the scanning electron microscope, respectively. The digital image of the polymer layer of the mat | matte of Example 1 with the magnifications of 50 times and 200 times with the scanning electron microscope, respectively. The digital image of 200-times multiplication factor of the die-cut edge part of the mat | matte of Example 1 by a scanning electron microscope. The digital image of the magnification of 200 times with the scanning electron microscope of the laser cut edge part of the mat | matte of Example 1. FIG. 1 is a flowchart of one embodiment of a process for manufacturing a mat according to the present invention having suction holes vacuum formed in a polymer layer.

  Referring to FIG. 1, an exemplary mat 10 described herein includes a nonwoven inorganic layer 11, a first polymer layer 12, an optional second polymer layer 13, an optional adhesive 14, and an optional adhesive. The release liner 15 is provided.

  Referring to FIG. 2, an exemplary mat 20 described herein includes a nonwoven inorganic layer 21, a first polymer layer 22, an optional expandable layer 26, and an optional second polymer layer 23. Have.

  Referring to FIG. 3, an exemplary mat 30 described herein has a nonwoven inorganic expandable layer 31, a first polymer layer 32, and an optional second polymer layer 33.

  Referring to FIG. 4, the pollution control device 110 includes a metal casing 111 having a generally frustoconical inlet 112 and an outlet end 113, respectively. Disposed within the casing 111 is a pollution control element 120 surrounded by a mat 130 according to the present disclosure. Although the mounting mat is tight to the monolithic element 120 in the casing 111, it serves to elastically support and hold, seal the gap between the pollution control element casings 111, and the exhaust gas prevents the pollution control element 120. Prevent or reduce (preferably minimize) bypassing.

  Referring to FIG. 5, the pollution control device 210 includes a metal casing 211 having a generally frustoconical inlet 212 and an outlet 213, respectively, and a heat shield 216. Disposed within the casing 211 is a pollution control element 220 surrounded by a first mat 230 according to the present disclosure. The mounting mat is tight to the monolithic element 220 in the casing 211, but serves to elastically support and hold, sealing the gap between the pollution control element casings 211, and exhaust gases to prevent the pollution control element 220. Prevent or reduce (preferably, minimize) bypassing. The second mat 240 according to the present disclosure is disposed between the casing 211 and the heat shield. The mat 240 serves to insulate.

  Referring to FIG. 6, the exhaust pipe 119 includes a double wall having a first outer metal wall 122 and a second inner metal wall 120. The nonwoven mat 124 according to the present disclosure is disposed in the gap between the outer wall 122 and the inner wall 120 to provide thermal insulation. The double wall of the exhaust pipe 119 surrounds an interior space 126 through which exhaust gas flows when the exhaust pipe 119 is used in an automobile exhaust system.

  As used herein, a “fiber” has a length of at least 5 micrometers and an aspect ratio (ie, length to diameter) of at least 3: 1.

  Exemplary inorganic fibers include various oxides such as silicates, aluminates, alumino-silica compounds, zircon, biosoluble compositions (eg, calcium magnesium silicate, and magnesium silicate), glass compositions (eg, S-glass and E-glass), amorphous, crystalline, and partially crystalline compositions, and mineral fibers (basalt), mineral cotton, and combinations, plus carbides (eg, silicon carbide and silicon carbide), nitriding Products (eg, silicon nitride and boron nitride), and combinations thereof.

In some embodiments, the inorganic fiber layer has a softening point and a total of 95 weight percent or less of SiO ₂ (if present) and Al ₂ O ₃ (if present) based on the total weight of the inorganic fibers. Including glass (i.e., amorphous material) (i.e., material obtained from a molten and / or vapor phase that does not have any long-period crystal structure), wherein the glass is ASTM C338-93 (2008) ( The disclosure of which is incorporated herein by reference) and has a softening point of at least 400 ° C. Exemplary glass fibers include, for example, aluminum magnesium silicate glass fibers.

  Exemplary aluminum magnesium silicate glass fibers include E-glass fibers, S-glass fibers, S-2 glass fibers, R-glass fibers, and mixtures thereof. E-glass, S-glass, and S-2 glass are commercially available from, for example, Advanced Glassfiber Yarns, LLC, Aiken, SC. R-glass is commercially available, for example, from Saint Gobain Vetrotex, Chambery, France.

In some embodiments, the inorganic fiber layer comprises refractory ceramic fibers (eg, aluminosilicate fibers (such as annealed amorphous aluminosilicate fibers), alumina fibers, silica fibers, and basalt fibers). “Refractory” in the context of refractory ceramic fibers refers to an amorphous artificial inorganic material made by melting, blowing or spinning a calcined kaolin clay or a mixture of alumina and silica. Other oxides such as zirconia, titania, magnesia, iron oxide, calcium oxide, and alkalis may also be present. The SiO ₂ content of the refractory material is greater than 20 weight percent, Al ₂ O ₃ is greater than 20 wt%, and SiO ₂ and Al ₂ O ₃ comprise a total of at least 95% inorganic material. Optionally, the refractory ceramic fibers may be partially or fully crystallized by heat treatment. Exemplary aluminosilicate amorphous refractory ceramic fibers include blown or spun amorphous refractory ceramic fibers (for example, commercially available from Thermal Ceramics (Augusta, GA) under the trade designations “KAOWOOL” and “CERAFIBER”, and Corporation, Niagara. The product name “FIBERFRAX” is available from Falls (NY).

  In some embodiments, the inorganic fiber layer is a polycrystalline ceramic fiber (eg, from Saffil Automotive (Chelsea, MI) under the trade name “SAFFIL”, and from Mitsubishi Chemicals USA, Inc. (Cheesepeake, VA)). Etc. which are marketed under “MAFTEC”).

  In some embodiments, the inorganic fiber layer comprises biosoluble fibers (eg, at least one of magnesium silicate fibers or calcium magnesium silicate fibers).

  As used herein, “biosoluble inorganic fiber” refers to an inorganic fiber that is degradable within a physiological medium or a simulated physiological medium. Physiological medium refers to, but is not limited to, bodily fluids that are typically found in the airways, such as animal or human lungs. Exemplary biosoluble inorganic fibers include those composed of oxides of silicon, magnesium, and calcium (such as calcium magnesium silicate fibers). These types of fibers are typically referred to as calcium magnesium silicate fibers and magnesium silicate.

The biosoluble fibers are, for example, Unifrax Corporation (Niagara Falls, NY) under the trade names “ISOFRAX” and “INSULFRAX”, Nutec Fiberate, Monterrey (Mexico) under the trade names “SUPERMAG 1200”, Ga ) Under the trade name “SUPERWOOL”. “SUPERWOOL 607” biosoluble fiber includes, for example, 60-70 weight percent SiO ₂ , 25-35 weight percent CaO, 4-7 weight percent MgO, and traces of Al ₂ O ₃ .

As used herein, the term “heat treated silica fiber” refers to an inorganic fiber comprising at least 95 weight percent SiO ₂ , wherein the fiber is at a heat treatment temperature of at least 400 ° C. during a heat treatment time of at least 5 minutes. Has been exposed.

Exemplary heat treated high silica content fibers are available, for example, from Hitco Carbon Composites, Inc. (Gardena, CA) commercially available under the trade name “REFRASIL”. For example, “REFRASIL F100” fiber contains about 96 to about 99 weight percent SiO ₂ .

Basalt fibers are formed from mineral basalt. Basalt is a hard and dense volcanic rock that can be found in most countries. Basalt is ground, washed, melted and fed to a platinum-rhodium extrusion bushing to form continuous filaments. Since fibers derived from mineral composition of the fibers may vary, but generally SiO ₂ of about 45 to about 55 weight percent, of from about 2 to about 6 weight percent alkali, from about 0.5 to about 2% by weight TiO _2, from about 5 to about 14 percent by weight of FeO, from about 5 to about 12 percent by weight of MgO, at least about 14 weight percent _Al 2 _{O 3,} and often, nearly composition to about 10 percent by weight of CaO Have.

  Optionally, the nonwoven layer, or another layer of the mat described herein required for expansion, further comprises an expandable material (eg, vermiculite). In some embodiments, it is preferred that the mat is non-expandable (ie, does not include an expandable material (eg, does not include vermiculite)). The expandable material may be present in the nonwoven layer and / or as one or more separate layers. As used herein, “non-expandable” refers to a material that exhibits less than 10% free expansion with respect to thickness under the same conditions. Some non-intumescent materials expand less than 8 percent, less than 6 percent, less than 4 percent, less than 2 percent, or less than 1 percent when heated.

  In some embodiments, the nonwoven layers described herein further contain an organic binder in an amount up to 7 (or more) weight percent, based on the weight of the nonwoven layer. When multi-layer mats including nonwoven layers are used at high temperatures, such as those typically encountered in pollution control devices, the organic binder is typically baked off.

  The nonwoven layers described herein may be manufactured using, for example, wet (typically wet laid) or dry (typically dry laid) processes known in the art. Optionally, the nonwoven layers described herein may be heat treated.

  In some embodiments, the inorganic fibers contain no shots or contain very small amounts of shots (eg, less than 1 wt% based on the total weight of the fibers), while in other embodiments, shots The content may exceed 50% by weight, based on the total weight of the fiber.

  Optionally, at least the nonwoven layer of some embodiments of the mounting mat described herein is needle punched (i.e., fully or partially (e.g. In the form, there is a physical entanglement of the fiber in the part by completely) penetrating. The nonwoven fabric mat can be needle punched using a conventional needle punching device.

  Optionally, some embodiments of the mounting mat described herein refer to prior art (eg, US Pat. No. 4,181,514 (Lefkowitz et al.), Which discloses stitchbonding of nonwoven mats. Stitch-bonded with reference to the teachings of the law).

  The expandable layer includes at least one type of expandable material. Examples of the expandable layer further include inorganic fibers, organic binders, plasticizers, wetting agents, dispersants, antifoaming agents, latex coagulants, fungicides, filler materials, inorganic binders, and organic fibers. it can.

  Exemplary intumescent materials include non-intumescent vermiculite, hydrobiotite, water-swellable synthetic tetrasilicate fluoromica, as described in US Pat. No. 3,001,571 (Hatch), US Pat. Examples include alkali metal silicate granules, expandable graphite, or combinations thereof as described in US Pat. No. 4,521,333 (Graham et al.). Alkaline metal silicate granules are commercially available, for example, from 3M Company (St. Paul, MN) under the trade name “EXPANTROL 4BW”. Expandable graphite can be obtained, for example, from UCAR Carbon Co. , Inc. (Cleveland, OH) under the trade name "GRAFOIL GRADE 338-50". Non-intumescent vermiculite is available, for example, from Metals Inc. (New York, NY). Depending on the application, the expandable material is selected from non-expandable vermiculite, expandable graphite, or combinations thereof. Vermiculite may be treated with a salt such as, for example, ammonium dihydrogen phosphate, ammonium nitrate, ammonium chloride, potassium chloride, or other soluble salts known in the art.

  The expandable layer often contains at least 5, at least 10, at least 20, at least 40, or at least 60 weight percent expandable material, based on the weight of the expandable layer. Depending on the intumescent layer, the layer may be free of inorganic fibers. In other expandable layers, the layer may be free of inorganic and organic fibers. In yet other expandable layers, the layer contains 5 to about 85 weight percent expandable material and less than 20 weight percent organic binder, based on the weight of the expandable layer. Inorganic fibers are included in several intumescent layers.

Exemplary intumescent layers are commercially available, for example, from 3M Company (St. Paul, MN) under the tradenames “INTERRAM 100”, “INTERRAM 200”, “INTERRAM 550”, and “INTERRAM 2000 LT”. These layers typically have a bulk density of about 0.4 to about 0.7 g / cm ^3, and about 1050 g / ^{m 2} ~ about 8140G / weight per unit area of ^{m 2.} Another exemplary intumescent layer is commercially available, for example, from 3M Company under the trade designation “INPE 570”. This layer is typically about 1050 g / ^{m 2} ~ about 4070 g / ^m has a weight per unit area of ^2, containing compatible inorganic fibers European unclassified fiber regulations.

  In some embodiments of the mats described herein that include an expandable layer, the nonwoven layer contains glass fibers and the expandable layer contains vermiculite.

  Optionally, edge protectors may be added to the mats described herein. The edge protector can be, for example, a stainless steel wire wound around the edge, as described in US Pat. No. 5,008,086 (Merry) (incorporated herein by reference). . Other suitable edge protection materials include, for example, braided or rope-like, as described in US Pat. No. 4,156,533 (Close et al.), Which is incorporated herein by reference. Glass, ceramic, or metal fiber. Edge protection materials are described, for example, in European Patent Nos. 639 701 A2 (Howorth et al.), 639 702 A2 (Howorth et al.), And 639 700 A2 (Strom et al.), All of which are incorporated herein by reference. May be formed from a composition having glass particles as described in).

  The thickness of a particular layer in the mat can be variable depending on the particular application. In some embodiments, the thickness of the expandable layer (if present) is less than or equal to the thickness of each nonwoven layer. In some applications, the thickness of the expandable layer (if present) is no greater than 50 percent, no greater than 45 percent, no greater than 40 percent, no greater than 35 percent, no greater than 30 percent, no greater than 25 percent, or 20 percent or less.

  In some embodiments, the nonwoven layers described herein have a thickness in the range of 1 mm to 35 mm (in some embodiments, in the range of 5 mm to 25 mm, 5 mm to 20 mm, or even 5 mm to 15 mm). Have In some embodiments, the expandable (including non-woven expandable) layers described herein range from 1 mm to 25 mm (in some embodiments, 1 mm to 20 mm, 1 mm to 15 mm, or even 1 mm. Thickness). In some embodiments, the mats described herein have a thickness in the range of 3 mm to 50 mm (in some embodiments, in the range of 5 mm to 35 mm, 5 mm to 20 mm, or even 5 mm to 10 mm). Have.

  In some embodiments, the nonwoven mats and nonwoven layers described herein further comprise a second polymeric layer that adheres to the second main layer. Typically, the thickness of the second polymer layer is up to 35 micrometers (in some embodiments, up to 30, 25, 20, 15, or even up to 10 micrometers, In some embodiments, it is in the range of 10 micrometers to 25 micrometers).

  A variety of thermoplastic and / or thermoformable polymers are useful for the polymer layer. Exemplary polymeric layers include polypropylene and polyethylene (eg, low density polyethylene and linear low density polyethylene), polyurethane, polyamide, polybutadiene, polycarbonate, polystyrene, polyester, copolymers, and blends thereof. The polymer layer is three-dimensional (ie, the polymer layer generally matches the outer surface of these fibers), where the polymer material has a topographic change in the “z” direction of the polymer surface. It has an overall three-dimensional structure that exceeds the average thickness of the polymeric film layer, and is typically at least partially within the applied major surface (ie, at least partially within the major surface layer). (See, for example, FIGS. 7 and 8, polymer layers 71 and 81, respectively, on the major surface of the nonwoven layer with fibers 81 and 82, respectively). The three-dimensional polymer layer is typically in intimate contact with the exposed fibers on the exposed major surface that it contacts. Typically, the bonding force between the three-dimensional polymer film and the fiber layer is larger than the bonding force of the fiber layer.

A polymer layer may be provided for the manufacture of the mats described herein, for example
Providing a non-woven fabric layer comprising inorganic fibers, which is a non-woven fabric layer having first and second major surfaces that normally face each other;
Applying a vacuum to the second main surface of the nonwoven layer;
Providing a mat by attaching a first polymer layer to the first main surface. Optionally, the method includes applying a vacuum to the first polymer layer deposited on the first major surface, and depositing a second polymer layer on the second major surface to produce a second high layer. Providing a mat having a molecular layer. It is desirable to have perforations present in at least the first polymer layer. Such perforation facilitates the process of attaching the second polymer layer to the nonwoven layer by a vacuum process. Due to the perforations in the first polymer layer, air can pull the nonwoven layer through the first polymer layer, thereby creating a vacuum in the nonwoven layer on the second major surface. The second polymer layer can be pulled.

  For example, the polymer layer used in the mats described herein can be perforated to form at least one and preferably a plurality of vacuum formed suction holes through the polymer layer. The pores formed through the first polymer layer can be pulled through the first polymer layer by vacuum when depositing the second polymer layer. “Suction hole” refers to a hole formed through a polymer layer when the polymer layer is disposed on the main surface of the nonwoven layer containing inorganic fibers and pulled opposite the main surface of the nonwoven layer in a vacuum. While the polymer layer is heated to the softening point, and (a) pulling the polymer layer in contact with the inorganic fibers in the nonwoven layer by vacuum, and (b) one or more passing through the polymer film It makes it possible to form suction holes. The heating process can cause local melting in the polymer layer and promotes vacuum to form suction holes.

  Pulling the polymer layer in contact with the inorganic fibers results in the polymer layer being formed into a three-dimensional polymer layer. The suction holes are typically formed in a region of the polymer layer that extends over the entire space between the inorganic fibers on the main surface of the nonwoven fabric layer. See, for example, the suction holes (ie, black dots) seen in FIGS. The polymer layer has a certain area and can include a plurality of vacuum-formed suction holes. The suction holes are typically unevenly distributed throughout the area of the polymer layer. Each suction hole typically has a different hole shape. Each suction hole is often an asymmetrical hole, such as that shown in FIGS.

  Referring to FIG. 11, in one process of forming such vacuum formed suction holes, a station 44 for unwinding a rolled web 41 which is a nonwoven layer or mat material, a roll which is a polymer layer or sheet material. A station 46 for unwinding the web 42, a guide roller 48 for guiding and placing the polymer material web above the upper main surface of the nonwoven material web 41, and a maximum of three locations disposed under the nonwoven material web 41. A vacuum box having a plurality of vacuum zones 52a, 52b, and 52c, a heat source 54 (eg, an electrical heating element) disposed above the polymeric material web 42, and a resulting web 50 that is a mat material (ie, at least A station 60 for winding the polymer layer 42 and the nonwoven fabric layer 41) into a roll; , To use the device 40. Station 60 pulls mat web 50 so that individual webs 41 and 42 pass through heating zone 56 followed by refrigeration or cooling zone 58.

  The nonwoven web material 41 is sufficiently porous to allow sufficient vacuum to be created through the nonwoven material, and the web that is a polymeric material is pulled down against the upper major surface of the nonwoven web 42 (ie, Aspirated). Due to the vacuum force drawn by the first vacuum zone 52a, the webs 41 and 42 are brought together while being transported past the guide roller 48. While the webs 41 and 42 are carried through the heating zone 56, heat from the heat source 54 is radiated in the direction of arrow 55 to at least soften or partially melt the polymeric web 42. At the same time that the polymeric web 42 softens and / or melts in the zone 56, the vacuum generated in the vacuum zone 52b is controlled so that the fibers of the nonwoven material are deformed into a three-dimensional shape. Can be pulled. In particular, when the web 42 is softened or melted, suction holes can be formed through the polymer web 42 by the vacuum in the zone 52b. Once the suction holes are opened, the air heated by the heat source 54 can be drawn into the nonwoven web material 41 through the suction holes. This additional heat from the heated air (see arrow 55) can promote softening and / or melting of the web 42, thereby increasing the number of suction holes formed in the web 42, the existing suction holes. The dimensions of the polymer web 42, the bond between the polymeric web 42 and the nonwoven web 41 are promoted, or any combination thereof. The temperature in the cooling zone 58 is sufficiently lower than that in the zone 56 that softens and / or melts the polymeric material web 42 for curing and / or solidification. The vacuum applied to the zone 52c draws cold air in the direction of arrow 59 through the suction holes in the web 42 to cool the preheated webs 41 and 42. In addition to the cooling effect provided by the vacuum in zone 52c, the cooling of zone 58 can optionally be assisted by the use of conventional refrigeration or air conditioning equipment.

  Suction holes vacuum formed in the first web 42, which is a polymeric material, allow the second polymeric layer to be bonded to another major surface of the nonwoven web 41. For the application of the second polymer layer, the roll of mat web 50 taken up at station 60 can be placed at station 44 so that the orientation of the web 50 is such that the perforated polymer web 42 is below the nonwoven web 41. Placed so that another major surface of the web 41 is exposed and face up. Then, another device 42 of the same or different polymeric material can be attached to the exposed major surface of the web 41 using the apparatus 40 in a manner similar to that described above. The vacuum created in the zones 52a, 52b and 52c allows the vacuum in the nonwoven web 41 to be pulled by suction holes formed in advance in the first web.

  Optionally, the mat also includes one or more expandable layers, and optionally a polymer layer is applied to the major surface of the expandable layer using the methods described above.

  Optionally, a double-sided adhesive tape is applied to at least a portion of the exposed outer major surface of the first polymer layer. Optionally, the double-sided adhesive tape includes a release liner.

Preferably, the inorganic fiber layer is at least 300 g / m ² , 400 g / m ² , 500 g / m ² , 600 g / m ² , 700 g / m ² , 800 g / m ² , 900 g / m ² , 1300 g / m ² , 2000 g. / ^{m 2,} or even (in the embodiment of the ^part, the range of ^{300g / m 2 ~8500g / m 2} ) of at least 3100 g / ^{m 2} having a basis weight of.

  The nonwoven layers and mats described herein are 7 (based in some embodiments, 6, 5) in the finished state prior to heating above 500 ° C., depending on the situation, based on the total weight of the nonwoven fabric or mat. 4, 3, 2, 1 or less, or even zero) containing no more than weight percent organic material.

  The nonwoven layers and mats described herein are typically flexible enough to be wound around a 7.5 cm diameter rod without breaking. The mat is usually handled without breaking or cracking and can be wrapped around the pollution control element of the pollution control device. When wrapped around a pollution control element, the end of the multilayer mat may be stopped at various joints.

  The mat and nonwoven layers described herein can be cut using, for example, die cut or laser cut techniques. Applicants have observed that the use of die-cutting instruments often degrades the quality of adhesion between the polymer film and the nonwoven along the edge, so laser-cut edges are preferred. This partial delamination can affect mat performance and reduce performance (increased fiber shedding at exposed edges, interference with mat attachment process, etc.). It has been found that delamination of the polymer layer can be significantly limited when parts are cut from the mat described herein using a laser beam. In order to locally soften and / or melt the polymer layer around the fiber contained in the nonwoven fabric, the laser beam cuts the part using the laser beam, and then the main surface (including polymer film) and secondary Intersections with the surface, or edges that occur during cutting, are sealed. The laser beam can also seal secondary surfaces or edges that occur during cutting, preventing further fiber shedding.

  Referring to FIG. 9, in a 200 × digital image of a die cut edge of the exemplary mat described herein (Example 1) with a scanning electron microscope, a polymer layer 91, fibers 92, and polymers A mat having a die cut edge 93 of layer 91 is shown. Referring to FIG. 10, in a 200 × magnification digital image of a laser cut edge of an exemplary mat described herein (Example 1) by a scanning electron microscope, a mat having a polymer layer 1001 and fibers 1002. And a laser cut edge 1003 of the polymer layer 1001 is shown.

  As used herein, “fire resistance” in the fabric surrounding the mats described herein is determined by the softening point above 450 ° C. (ASTM C338-93 (2008), the disclosure of which is hereby incorporated by reference). Or a material having at least one of melting points, incorporated herein. Exemplary fire resistant cloths surrounding the mats described herein include glass cloth and silica cloth. Exemplary refractory cloths surrounding the mats described herein are trade names “AVS FIBER GLAST FABRICS”, “FLXGLAS HT TREATED FIBERGLASS FABRICS”, and “AVSIL S” from AVS Industries, LLC (New Castle, DE). It is commercially available from SILICA FABRICS.

  The metal casing can be made of materials known in the art for such use, including stainless steel.

Nonwoven mats can be used as thermal insulation materials to insulate various components of the exhaust system, including, for example, exhaust pipes, contamination control device inlet or outlet end cones, or internal combustion engine exhaust manifolds. The nonwoven mats described herein are useful, for example, in a pollution control device. A pollution control device typically includes a pollution control element (eg, a catalytic converter, a diesel particulate filter or a selective catalyst reduction element) mounted in a casing with the nonwoven mat described herein. In an exhaust system comprising a double wall exhaust component (eg, an exhaust pipe, an end cone end cap, or another part of a pollution control device, and / or an exhaust manifold) and a nonwoven mat as described herein. The nonwoven mat may be mounted in the gap between the first outer wall and the second inner wall of the double wall part. Exemplary packing density is in the range of about ^{0.1g / cm 2 ~0.6g / cm 2} .

  Exemplary pollution control elements that can be mounted with the mounting mats described herein include gasoline pollution control elements and diesel pollution control elements. The pollution control element may be a catalytic converter or a particulate filter, or a trap. Catalytic converters contain a catalyst that is normally coated onto a monolithic structure that is mounted in a metal housing. The catalyst is usually adapted to operate and be effective at temperature requirements. For example, for use with gasoline engines, catalytic converters should typically be effective at temperatures in the range of 400 ° C to 950 ° C, but for diesel engines, lower temperatures (typically Is generally 350 ° C. or lower). Metallic monoliths are also used occasionally, but monolithic structures are typically ceramic. In order to suppress air pollution, the catalyst oxidizes carbon monoxide and hydrocarbons in the exhaust gas and reduces nitrogen oxides. In gasoline engines, all three of these pollutants can react simultaneously in a so-called “three-way converter”, but most diesel engines are equipped with only a diesel oxidation catalytic converter. Catalytic converters that reduce nitrogen oxides, whose use is limited to diesel engines today, generally consist of separate catalytic converters. Examples of pollution control elements used in gasoline engines include, for example, Corning Inc (Corning, NY) or NGK Insulators, LTD. Examples thereof include those formed from cordierite commercially available from (Nagoya, Japan) or metal monoliths commercially available from, for example, Emitec (Lohmar, Germany).

  Suitable selective catalyst reduction elements are described, for example, in Corning, Inc. , Corning, NY.

  Diesel particulate filters or traps are typically wall flow filters, which typically have a honeycomb-like monolithic structure made from a ceramic material with a porous crystal structure. Alternating cells of a honeycomb-like structure are typically embedded so that exhaust gas enters one cell and is forced through the porous walls of one cell and exits the structure through adjacent cells. . In this way, small soot particles present in the diesel exhaust are recovered. Suitable diesel particulate filters formed from cordierite are, for example, Corning Inc. And NGK Insulators, Inc. Commercially available. Diesel particulate filters formed from silicon carbide are, for example, Ibiden Co. Ltd .. (Japan), for example, described in JP2002047070A published on February 12, 2002.

  The advantages and embodiments of the present invention are further illustrated by the following examples, whose particular materials and amounts listed in these examples, as well as other conditions and details, are to be construed as unduly limiting the present invention. Should not be done. All parts and percentages are on a weight basis unless otherwise stated.

Example 1
1. Unroll one roll of 76 cm (30 inches) wide, 15 micrometers (0.006 inches) thick transparent low density polyethylene linear film (obtained under the trade name “ALTEX” from FlexSol Packaging (Chicago IL)). Mounting mat material which is a 66 cm (26 inch) wide, 2000 gram per square meter web on a vacuum table with eight 1.3 cm (0.5 inch) wide slots placed at 54 cm (1 inch) intervals (Material sold under the trade name “INTERRAM ™ MAT MOUNT 1220 NC” from 3M Company (St. Paul, MN)). A stainless steel carrier web was used to move the film and mat up the vacuum box. The film was heated using two 2000 watt infrared lamps (model SRU 1615HT, Inflatetech (Gardenia, Calif.)) And the film and mat were laminated together. The first lamp is suspended 1.25 inches (3.2 cm) from the web, and the second lamp is located adjacent to the first lamp and is suspended from the film surface (3 inches ( 7.6 cm)), the lamp was positioned to be centered above the vacuum slot. The line speed was 2.1 meters / minute (7 feet / minute), which pulled the film close to the fabric layer surface, exposed to the lamp and cooled to room temperature, then the mat surface and film With sufficient evacuation (typically about 10.2 to 20.3 kPa (3 to 6 inches of mercury)) to produce a bond in between that exceeds the bond strength of the mat.

  7 and 8 showing the mat of Example 1 (having the polymer layers 71 and 81 respectively on the main surface of the nonwoven fabric layer having the fibers 81 and 82, respectively) are 50 times and 200 times magnification, respectively.

  The mat of Example 1 was cut with both a conventional metal rule die and a laser (2 kilowatts at 381 cm / min (150 inches / min)) to obtain die cut edges and laser cut edges. FIG. 9 is a digital image of a 200 × magnification of the die cut edge of the mat of Example 1 using a scanning electron microscope, showing the polymer layer 91, the fiber 92, and the die cut edge 93 of the polymer layer 91. . FIG. 10 is a digital image of 200 × magnification of the laser cut edge of the mat of Example 1 using a scanning electron microscope, showing the polymer layer 1001, the fiber 1002, and the laser cut edge 1003 of the polymer layer 1001. ing.

  The mat of Example 1 was wound around a rod having a diameter of 7.6 cm (3 inches) without breaking.

(Example 2)
In Example 2, a second layer of low density polyethylene linear film (“ALTEX”) was also laminated on the lower surface (ie, both major surfaces of the mounting mat were laminated with low density polyethylene linear film). Except for the above, it was prepared by the method described in Example 1. In addition, the line speed was reduced to 1.8 meters / minute (6 feet / minute), the film was pulled in close contact with the fabric layer surface, exposed to the lamp and cooled to room temperature, after which the mat surface and film were Sufficient vacuum was applied to create a bond in between that exceeded the mat's bond strength (typically about 16.9 to 37.3 kPa (5 to 11 inches of mercury)).

  The mat of Example 2 wrapped around a 7.6 cm (3 inch) diameter rod without breaking.

(Example 3)
Example 3 was prepared by the method described in Example 1 except that the mounting mat material was 5100 grams / square meter (a material sold by 3M Company under the trade name “INTERRAM ™ MAT MOUNT 700”), The line speed is 1.8 meters / minute (6 feet / minute), the film is pulled close to the fabric layer surface, exposed to lamp and cooled to room temperature, then the mat between the mat surface and the film Sufficient vacuum was applied to produce a bond that exceeded the bond strength (typically about 16.9-37.3 kPa (5-11 inches of mercury)).

  The mat of Example 3 was wound around a 7.6 cm (3 inch) diameter rod without breaking.

Example 4
Example 4 was prepared by the method described in Example 1 except that the mounting mat material was 5800 grams / square meter (material sold by 3M Company under the trade name “INTERRAM ™ MAT MOUNT 7220X”), The line speed is 1.8 meters / minute (6 feet / minute), the film is pulled close to the fabric layer surface, exposed to lamp and cooled to room temperature, then the mat between the mat surface and the film Sufficient vacuum was applied to produce a bond that exceeded the bond strength (typically about 16.9-37.3 kPa (5-11 inches of mercury)).

  The mat of Example 4 was wound around a 3 inch (7.6 cm) diameter rod without breaking.

(Example 5)
A web of INTERRAM ™ Mounting Mat Material 1220NC (3M Company (St. Paul, MN)) showing 2000 grams per square meter is placed above the six vacuum slots 1.27 cm (0.5 inches) in the middle 3. Carry on a metal mesh belt at 3.66 meters / minute (12 feet / minute) over 81 cm (1.5 inches). A vacuum slot maintains a pressure differential of about 40 cm of water (1.16 inches of mercury (3.93 kPa)) across the mat. A 0.0015 mm (0.0006 inch) thick linear low density polyethylene film (FlexSol Packaging Corp. (Bunsville, Minn.)) Is unrolled on top of the mat surface and hung 2.54 cm (1.0 inch) above the mat surface. The 31.8 cm (15 inch) wide heating lamp (RayLow P1560AX019 0852 (460 volts 1800 watts) from WatLow (St. Louis, Mo.)) is used to thermally bond to the mat. When measuring with a Scotchtrak Heat Tracer non-contact measuring device (model IR-18EXL3 of #M Company (Austin, TX)), when the lamp surface temperature is about 427 ° C. (800 ° F.) and the heating area directly under the lamp is exited. Sufficient power is supplied to the heating lamp to maintain a mat surface temperature of about 149 ° C. (300 ° F.).

Exemplary Mat Embodiments 1.
A non-woven layer having first and second main surfaces that are normally opposed to each other, the non-woven layer comprising inorganic fibers;
A first polymer layer that adheres in contact with at least a portion of the inorganic fibers that form the first major surface, and includes at least one vacuum formed suction hole formed therethrough A mat comprising: a first polymer layer; Such a first polymer layer is preferably a three-dimensional polymer layer.
2. Embodiment 1, wherein the first polymer layer has a certain area, includes a plurality of vacuum-formed suction holes, and the suction holes are unevenly distributed over the entire area of the first polymer layer. The mat described in.
3. The mat of embodiment 2, wherein each of the suction holes has a different hole shape.
4). The mat according to embodiment 2 or 3, wherein each of the suction holes is an asymmetric hole.
5). Embodiments 1 to 1, further comprising an inflatable layer having first and second main surfaces that normally face each other, wherein the first main surface of the intumescent layer adheres to the second main surface of the nonwoven layer. 5. The mat according to any one of 4.
6). The mat according to any one of Embodiments 1 to 4, wherein the non-woven fabric layer is a non-woven expandable layer further containing an expandable material.
7). Embodiment 7. The mat of any one of embodiments 1-6, wherein the nonwoven layer has an organic content of 7 weight percent or less, based on the total weight of the nonwoven layer.
8). Embodiment 7. The mat of any one of embodiments 1-6, wherein the nonwoven layer has an organic content of 1 weight percent or less based on the total weight of the nonwoven layer.
9. The mat of any one of embodiments 1-6, wherein the nonwoven layer has an organic content of zero weight percent, based on the total weight of the nonwoven layer.
10. Embodiment 10. The mat of any one of embodiments 1-9, wherein the first polymer layer has an average thickness of up to 35 micrometers.
11. Embodiment 10. The mat of any one of embodiments 1-9, wherein the first polymer layer has an average thickness in the range of 5 micrometers to 25 micrometers.
12 Embodiment 10. The mat of any one of embodiments 1-9, wherein the first polymer layer has an average thickness in the range of 10 micrometers to 25 micrometers.
13. Embodiment 13. The mat of any one of embodiments 1-12, wherein the first polymeric layer comprises a thermoplastic polymer (eg, at least one of polypropylene or polyethylene).
14 And further comprising a second polymer layer attached such that the nonwoven layer is between the first polymer layer and the second polymer layer, wherein the second polymer layer is formed therethrough. Embodiment 14. A mat according to any one of the preceding embodiments, comprising at least one vacuum-formed suction hole. Such a second polymer layer is preferably a three-dimensional polymer layer.
15. Embodiment 14 wherein the second polymer layer has a constant area, includes a plurality of vacuum formed suction holes, and the suction holes are unevenly distributed over the entire area of the second polymer layer. The mat described in.
16. The mat according to embodiment 14 or 15, wherein each of the suction holes has a different hole shape.
17. Embodiment 17. A mat according to any one of embodiments 14-16, wherein each such suction hole is an asymmetrical hole.
18. Embodiment 18. The mat of any one of embodiments 14 through 17, wherein the second polymeric layer comprises a polymer that is thermoplastic.
19. Embodiment 19. The mat of any one of embodiments 14-18, wherein the second polymer layer has an average thickness of up to 25 micrometers.
20. Embodiment 19. The mat of any one of embodiments 14-18, wherein the second polymeric layer has an average thickness in the range of 5 micrometers to 25 micrometers.
21. Embodiment 19. A mat according to any one of embodiments 14-18, wherein such second polymeric layer has an average thickness in the range of 10 micrometers to 25 micrometers.
22. Such inorganic fibers, based on the total weight of the glass fibers, including glass fibers comprising SiO ₂ and _Al 2 _{O 3} in total of 95 weight percent, mat according to any one of embodiments 1-21.
23. The mat of any one of embodiments 1-22, wherein the inorganic fibers comprise refractory ceramic fibers.
24. The mat according to any one of embodiments 1-23, wherein the inorganic fibers comprise polycrystalline ceramic fibers.
25. The mat according to any one of Embodiments 1 to 24, wherein the inorganic fibers comprise biosoluble fibers.
26. Such nonwoven layer has a basis weight of at least 900 g / ^{m 2,} mat according to any one of embodiments 1-25.
27. Mat according to such nonwoven ^layer having a basis weight in the range of ^{800g / m 2 ~8500g / m 2} , any one of embodiments 1-25.
28. Embodiment 28. The mat of any one of embodiments 1-27, wherein the fibers have a diameter of at least 5 micrometers.
29. Embodiment 29. The embodiment of any one of embodiments 1-28, wherein the nonwoven layer is subjected to at least one of needle punching, manufacturing by a wet laid process, and manufacturing by a dry laid process, or any combination thereof. mat.
30. The mat of any one of embodiments 1-29, wherein the nonwoven layer contains 7 weight percent or less organic material, based on the total weight of the mat, in a finished state prior to heating above 500 ° C. .
31. The mat of any one of embodiments 1-30, wherein the nonwoven layer has a finished bulk density in the range of 0.05 g / cm ^{3 to} 0.3 g / cm ³ .
32. The mat of any one of embodiments 1-31, wherein the nonwoven layer has an average thickness in the range of 3 mm to 50 mm.
33. 33. A mat according to any one of embodiments 1-4 and 7-32, wherein the mat is non-expandable.
34. The mat according to any one of Embodiments 1-4 and 7-32, wherein the mat does not comprise vermiculite.
35. Embodiment 35. The mat of any one of embodiments 1-34, wherein the nonwoven mat is flexible enough to be wrapped around a 7.5 cm diameter rod without breaking.
36. The mat of any one of embodiments 1-35, having at least one laser cut edge.
37. The mat of any one of embodiments 1-4 and 7-36, further comprising a first expandable layer attached to the second major surface of the nonwoven layer.
38. 38. The mat according to any one of embodiments 1-37, wherein the first polymer layer has an exposed outer main surface and has a double-sided adhesive tape affixed on at least a portion thereof.
39. The mat of embodiment 38, wherein such a double-sided adhesive tape comprises a release liner.
40. Mat according to such nonwoven ^layer having a basis weight in the range of ^{800g / m 2 ~3000g / m 2} , any one of embodiments 1-39.
41. 41. A mat according to any one of the embodiments 1-40, in combination with a refractory cloth surrounding the mat.

Exemplary Contamination Prevention Device Embodiments 1. A pollution control device comprising a pollution control element mounted in a casing together with the mat according to any one of embodiments 1-41 of the mat.
2. The pollution control device according to embodiment 1, wherein the pollution element is one of a catalytic converter, a diesel particulate filter or a selective catalyst reduction element.

Exemplary exhaust system embodiments 42. An exhaust system comprising a double wall exhaust component and a mat according to any one of embodiments 1-41, wherein the mat is disposed in a gap between the walls of the double wall exhaust component.
2. The exhaust system of embodiment 1, wherein the double wall exhaust component is an exhaust pipe.
3. The exhaust system of embodiment 1, wherein the double wall exhaust component is a terminal cone of a pollution control device.
4). The exhaust system of embodiment 1, wherein the double wall exhaust component is an exhaust manifold.

Exemplary Article Embodiments An object having a radius r;
42. An article comprising the mat according to any one of embodiments 1-41 that is wound substantially around the object radius without physically overlapping.
2. The article of embodiment 1, wherein the mat has a wound length within 99 percent of 2πr.
3. The article of embodiment 1, wherein the mat has a wound length within 98 percent of 2πr.
4). The article of embodiment 1, wherein the mat has a wound length within 95 percent of 2πr.

  Without departing from the scope and spirit of the invention, foreseeable modifications and alterations of the invention will be apparent to those skilled in the art. The present invention should not be limited to the embodiments described in this application for purposes of illustration.

Claims (11)

A mat for use in a housing of a pollution control device,
A non-woven layer having first and second main surfaces that are normally opposed to each other, the non-woven layer comprising inorganic fibers;
A first polymer layer adhering in contact with at least a portion of the inorganic fibers forming the first main surface, wherein the at least one vacuum formed formed through the polymer layer; A first polymer layer including suction holes;
A second polymer layer attached so that the nonwoven fabric layer is between the first polymer layer and the second polymer layer;
Including mat.   The mat of claim 1, wherein the nonwoven layer has an organic content of 7 weight percent or less based on the total weight of the nonwoven layer.   The mat according to claim 1 or 2, wherein the mat is non-inflatable.   4. An expansible layer having first and second major surfaces that normally face each other further, wherein the first major surface of the expansible layer adheres to the second major surface of the nonwoven layer. The mat according to any one of the above.   The mat according to claim 1 or 2, wherein the non-woven fabric layer is a non-woven expandable layer further containing an expandable material.   The mat according to any one of claims 1 to 5, wherein at least one of the first polymer layer and the second polymer layer is a three-dimensional polymer layer.   The mat according to any one of claims 1 to 6, wherein the nonwoven mat is sufficiently flexible so that it can be wound around a rod having a diameter of 7.5 cm without breaking. A pollution control device comprising a pollution control element mounted in the housing together with the mat according to claim 1.   An exhaust system comprising a double wall exhaust component and a mat according to any one of claims 1 to 7, wherein the mat is arranged in a gap between the walls of the double wall exhaust component. An object having a radius;
An article comprising: a mat according to any one of claims 1 to 7 wound substantially around the radius of the object without physically overlapping. A method of manufacturing a mat for use in a housing of a pollution control device, comprising:
Providing a non-woven fabric layer comprising inorganic fibers, which is a non-woven fabric layer having first and second major surfaces that normally face each other;
Applying a first polymer layer to the first main surface;
Applying a vacuum to the second major surface of the nonwoven layer to form at least one vacuum formed perforation through the first polymer layer;
Applying a second polymer layer to the mat such that the nonwoven layer is between the first polymer layer and the second polymer layer;
Applying a vacuum to the first polymer layer,
Manufacture of a mat that, when applying the second polymer layer, allows at least one vacuum formed perforation through the first polymer layer to be pulled through the first polymer layer by vacuum. Method.

Images